Package for shipping and storage of panel products

ABSTRACT

A package for storing and shipping flat panel products includes a shock- absorbing inner protective material, a telescoping outer packaging material, adjustable to the size of the product being shipped, and an outer binder, such as a plastic banding material. The inner wrapping material is provided around a circumferential edge of the product and is secured in place. The outer protective packaging material is provided around the wrapped product, adjusted to the appropriate size, and is bound in place with a plastic banding material which is wrapped longitudinally and secures the lateral and longitudinal position of the product within the package. The telescoping package includes slots for receiving and retaining the plastic banding material in position.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to earlier filed U.S. Provisional Application Ser. No. 60/510,647, filed Oct. 10, 2003, the contents of which are incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

The present invention is related to packaging for shipping products, and more particularly to packaging materials for shipping flat panel products.

Products which are generally narrow in depth and formed-in a sheet, plate or panel construction such as doors, windows, mirrors, and raw sheet materials including glass, plastic, stone, and various composite materials can be difficult to package and ship as they are prone to damage when dropped, particularly when dropped on their corners or edges. These types of products, referred to hereafter generally as “flat panel products” are typically packaged for shipping in an inner protective package enclosed in an outer shipping container. The inner protective package is typically constructed of a corrugated or paperboard material which is die cut to provide a pocket for receiving the package, and flaps which are folded over the product and taped or otherwise adhered over the product to retain the product in position, and away from the edges of the package, during shipping. Prior to being positioned in the pocket, the product is typically wrapped in a poly, plastic or other scratch and/or liquidresistant wrapping material to further protect the product during shipping. The outer packaging material is disposed around the inner package, enclosing the product and providing a location for placing shipping information on the package.

While methods for packaging flat panel products are therefore known in the art, there are a number of problems associated with these packaging methods. For example, to adequately protect the flat panel product provided within the package, each package must be individually sized to accept the particular product being shipped. Therefore, in production and packaging facilities where a number of different types of products are produced, an equivalent number of different types of shipping cartons must be stocked for packaging. Also, the products must be assembled into the packaging entirely by hand, and the packaging process is therefore labor intensive, relatively expensive, and slow, often taking longer than the actual production. Additionally, the packaging is relatively heavy, thereby contributing to increased labor difficulties and expenses in shipping. Furthermore, damage to the internal products remains a problem when using these types of packages, contributing significantly to the cost of both the product and shipping.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a package for shipping flat panel products. The package includes an inner protective packaging material disposed peripherally around an outer edge of the flat panel product, a size-adjustable outer packaging material enclosing the inner protective packaging material, and a binder provided around the outer packaging material for securing the outer packaging material to the inner protective packaging material. The binder retains the flat panel product within the package and suspends the inner protective packaging material and the product relative to at least one side wall of the size adjustable outer packaging material. In another aspect of the invention, the inner protective packaging material and flat panel product are spaced in suspension from said at least one sidewall of the size adjustable outer packaging material.

In yet another aspect of the invention, a package for shipping a flat panel product is provided. The package includes an inner shock-absorbing packaging material disposed around the circumference of the flat panel product. A telescoping outer packaging material comprising a plurality of slots on at least one pair of opposing edges is provided toward the wrapped package and a banding material provided over the outer packaging material. The banding material is received in the slots to bind the outer packaging material to the inner packaging material and the product.

In still another aspect of the invention, a package for shipping a flat panel product includes a strip of an inner protective packaging material wrapped peripherally around an outer edge of the flat panel product having side edges laterally spaced from opposing faces of the flat panel product to create a protected air space on each side of the flat panel product. An outer packaging material, having a certain lateral size and an adjustable longitudinal size, encloses the inner protective packaging material and product. The package further includes a binder wrapped longitudinally around the outer packaging material, and received in slots in opposed sidewalls of the longitudinal ends of the outer protective packaging material, wherein the binder supportively engages the inner protective packaging material in the slots to laterally support the inner protective packaging material and product within the outer protective packaging material.

These and other aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a packaged panel product and outer shipping package;

FIG. 2 is an exploded view of the packaged panel product of FIG. 1;

FIG. 3 is a partial view of the panel product received in the inner protective packaging material of FIG. 2;

FIG. 4 is a cutaway top view of the packed panel product of FIG. 2;

FIG. 5 is a view of the packaged panel product of FIG. 4 taken along the line 55;

FIG. 6 is a view of the panel product and inner protective wrapping material of FIG. 2 disposed on the outer protective packaging material prior to folding;

FIG. 7 is a view of the panel product and inner protective wrapping material of FIG. 2 disposed on the outer protective packaging material with the flaps folded; and

FIG. 8 is a view of the package of FIG. 7, with one of the front portions of the outer packaging material folded over to form an enclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the figures and more particularly to FIG. 1, a shipping package 11 constructed in accordance with the present invention is shown. The shipping package 11 comprises a protected panel product 10 enclosed inside of an outer shipping packaging 12. The protected panel product 10 and shipping packaging 12 protect the product from damage during shipping and further provide a location for mounting a shipping label.

Referring now to FIG. 2, the protected panel product 10 is a sheet or flat panel product 14 which is enclosed peripherally about its outer circumferential edge in a length of inner protective packaging material 16, which is itself enclosed in an outer protective package 21. The outer protective packaging material 21 is preferably, as shown here, a size-adjustable box constructed of two protective panels 18 and 20 which can be “telescoped” longitudinally to adjust to various lengths of panel products 14, as described below. The lateral dimension of the panels 18 and 20, however, is fixed, so the lateral dimension of the product 14 wrapped in inner protective packaging material 16 is less than or equal to the lateral dimension of the panels 18 and 20. If less, there will be a lateral air space between the wrapped product 14 and at least one sidewall of the outer protective packaging material 21, with the product 14 wrapped in inner protective packaging material 16 supported by the binder 24.

Each of the panels 18 and 20 includes both a back portion 34, a front portion 38, a side portion 36, and flaps 32 extending from opposing ends of each back portion 34. The back portion 34 is separated from the side portion 36 by a first crease line 40 and the side portion 36 is separated from the front portion 38 by a second crease line 42. A third crease line 44 separates the flap 32 from the back portion 34, while a fourth crease line 46 is provided in the flap 32 to allow the flap 32 to be folded, as described below. Each of the panels 18 and 20 further comprises slots 22, which are die cut or otherwise formed in the panels 18 and 20 in pairs on the side portions 36 of the panels 18 and 20 to receive a binder 24. The slots extend across the width of each side portion 36 and can extend into portions of each of the back portion 34 and front portion 38. The slots 22 receive the binder 24 which can be, as shown here, a strap or banding, such as a plastic banding material. The binder 24 is wrapped circumferentially around the protected panel product 10, extends through the slots 22, is pulled tight around the outer packaging 21, and has its ends seared to one another.

Referring now to FIG. 3, the inner protective packaging material 16 is a shockabsorbing resilient material selected to absorb force and protect the panel product 14 in the event it is dropped. The inner protection packaging material 12 is preferably a suspension wrap material such as SUS-RAP®, commercially available from the Sus-Rap Division of the Menasha Corporation in Danville, Va. The suspension wrap material is provided in continuous lengths which can be sized to a particular panel product 14, and includes Ashaped slots 26 which firmly suspend the panel product 14 to cushion the product from shocks and prevent breakage. The A-shaped slots 26 provide a reinforced wall around the product 14 which provides strong support for stacking and can serve to decrease damage during handling and warehousing. The outer edge of the suspension wrap material can comprise a series of radially externally directed corrugations 30 which are formed in a semicircular shape. These corrugations 30 further cushion the panel product 14 from damage, absorbing shocks and forces applied to the outside edge of the panel 14. As shown, the A-shaped slots 26 can include a plurality of pairs of slits 27 which are sized and dimensioned to receive an edge of a panel product 14 of a selected size.

When a panel product 14 is inserted within the A-shaped slot 26, the portion between the slits 27 is pressed down as shown in FIGS. 3 through 5, while the remaining portion of the A-shaped slots 26 extends radially inward toward the center of the product 14. The side edges of the inner protective packaging material 16 are laterally spaced from opposing faces of the flat panel product 14 so as to create a protected air space on each side of the flat panel product between the face of the product and a plane defined by the adjacent side edges of the packaging material. The air space protects the panel product 14 from a force or pressure applied to the front and/or back of the panel product 14. The suspension wrap material can further include a scratch-resistant film or coating, particularly when the product 14 comprises wood or other materials prone to scratching. In this application, a suitable product is commercially available under the tradename POLY SUS-RAP®, also available from the Sus-Rap Division of Menasha Corporation in Danville, Va.

Referring now to FIG. 4, a cutaway view of the protected panel product 10 is shown. Here, it can be seen that the panel product 14 is surrounded on all edges by a length of the inner protective material 16 and is received within the slits 27 formed in the A-shaped slots 26 as describe above such that, as shown in FIG. 3, the A-shaped portion extends radially inward from either side of the panel product 14 retaining the panel product in place, protecting it from external forces, and cushioning the edges of the panel product 14. Also as described above, semicircular corrugations 30 extend outwardly radially away from the base sections of the A-shaped slots 26. The outer protective packaging 21 which can comprise, for example, paperboard or corrugated craft, circumscribes the panel product 14 encased in the inner protective material 16, adjacent the corrugations 30. The outer protective packaging 21 further comprises slots 22, as described above, for receiving the binder 24. The binder 24 retains the inner protective material 16 and the outer protective material 21 around the circumference of the panel product 14, and supportively engages the inner protective packaging material 16 in the slots to laterally support the wrapped product 14 in the outer protective packaging material 21.

Referring now to FIG. 5, a detailed view of the receipt of the panel product 14 within the inner protective material 16 is shown. As described above, the panel product 14 is received within the slits 27 in the A-shaped slot 26, and semicircular corrugations 30 are directed outward toward the outer protective package material 21. The binder 24, here shown as plastic banding, is received in the slot 22 and retains both the inner protective packaging material 16 and the outer protective packaging material 21 against the panel product 14 and further retains the inner protective material 16 against the outer protective packaging material 21. As described above, the binding 24 further supports the wrapped product 14 laterally.

Referring again to FIG. 2, to assemble the panel product 14 within the protective panel product 10, the panel product 14 is initially wrapped peripherally about its outer edge with a length of the inner protective packaging material 16, and is positioned within the inner protective packaging material 16 with the A-shaped slots 26 extending radially inward and the corrugations 30 extending radially outward away from the product 14.

As described with reference to FIG. 3, the panel product 14 is slid into the inner protective packaging material 16 between the slits of one of a plurality of pairs of precut slits 27 which are sized and dimensioned to receive an edge of a panel product 14 of varying edge widths. Once the inner protective packaging material 16 is provided around the panel product 14, it is adhered in place, for example, by attaching a piece of tape or other adhesive to the open ends of the inner protective packaging material 16 circumscribing the edge of the panel product 14.

The wrapped panel product 14 is then positioned on the panels 20 and 18, which are arranged with their respective back portions 34 adjacent each other, and with the back 34 of one of the panels 18 and 20 overlapping the back of the other of the panels 18 and 20.

Referring now to FIG. 6, to adjust the size of the outer protective packaging material 21, the back of one of the panels 18 and 20 is slid over the back 34 of the opposing panel 18 or 20 until the side portions 36 each abut the inner protective packaging material 16. When the relative position of the panels 18 and 20 is sized for the panel product 14, the flaps 32 are folded along the crease line 46 to form, as shown in FIG. 7, a triangular wall 48, the base of the triangle being provided by the back portion 34 of the panels 18 and 20, and the walls provided by the folded flaps 32.

Referring now to FIG. 8, after the flaps 32 are folded, the fronts 38 of the panel 18 and 20, respectively, are folded over the panel product 14 to form an enclosure. Referring again to FIG. 2 and also to FIG. 1, after the front portions 38 of the panels 18 and 20 are folded over the product, the binder 24, here a plastic banding material, is attached through the slots 22, pulled tight across the outer packaging material 21, and adhered in place as, for example, by applying heat or a clip to attach the ends of the bands. The binder 24 is wrapped longitudinally around the outer packaging material 21 and received in the slots 22 to supportively engage the inner protective packaging material in the slots 22 and to laterally support the inner protective packaging material 16 and flat panel product 14 within the outer protective packaging material 21. The binding 24 suspends the inner protective packaging material 16 and the product 14 relative to at least one side wall of the size adjustable outer packaging material 20 and therefore protects the edges of the product during shipment. Prior to applying the binder 24, the panel 18 can also be optionally adhered to the panel 20 with a glue, tape, or other adhesive, to simplify the addition of the binder 24.

Referring now to FIG. 1, after the protected panel product 10 is assembled, it can be enclosed within an outer shipping package 12. The shipping package 12 is a paper, corrugated, or cardboard construction, and includes foldable flaps which are folded over the protective panel product 10 and adhered in place for shipping. A shipping label can be provided directly on the outer shipping package 12.

The packaging shown and described provides improved protection from damage by providing an air cell around the perimeter of the product to protect the product from damage due to drops and vibration during shipment. Because the outer packaging 21 can be telescoped to the appropriate size for the panel 14, inventory of packaging can be significantly reduced. The weight of the packaging is also reduced as compared to prior art packaging, reducing shipping cost. The packaging as described has been further shown to be effective in meeting shipping standards of the International Safe Transit Association Testing.

Although a specific embodiment of the present invention has been shown and described above, it will be apparent that a number of variations can be made within the scope of the invention. For example, although a specific suspension wrap material is described above, a number of similar suspension wrap products, also commercially available from the Menasha Corporation, can also be used. Furthermore, various other resilient and/or shockabsorbing protective materials including but not limited to foam, plastic, rubber, corrugated build-ups, corrugated die cuts, and other materials can also be used.

Furthermore, although the binder 24 is described above as a plastic banding material, various other adhesive devices including glue, tape, cinch-staples, stretch wrap, press seals, and other devices could also be used. Similarly, although the outer protective packaging 21 is described above as corrugated paperboard, corrugated plastic, laminated fiberboard, sheet plastic, shrink wrap, single face corrugated paper, and various other materials could also be used.

Additionally, a number of different types of flat panel products can be packaged as described including windows, glass, plastic, mirrors, composite materials, granite, entrance doors, shutters, shower doors, medicine cabinets, industrial cabinets, picture frames, glass, circuit board and similar products and devices.

While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention defined by the appended claims. 

1. A package for shipping a flat panel product, the package comprising: an inner protective packaging material disposed peripherally around an outer edge of the flat panel product; a size-adjustable outer packaging material enclosing the inner protective packaging material; and a binder provided around the outer packaging material for securing the outer packaging material to the inner protective packaging material to retain the flat panel product within the package and suspend the inner protective packaging material and the product relative to at least one side wall of the size adjustable outer packaging material.
 2. The package as defined in claim 1, wherein the inner protective packaging material comprises a resilient material.
 3. The package as defined in claim 1, wherein the inner protective packaging material and flat panel product are spaced in suspension from said at least one sidewall of the size adjustable outer packaging material.
 4. The package as defined in claim 1, wherein the inner protective packaging material comprises a shock-absorbing material.
 5. The package as defined in claim 1, wherein the inner protective packaging material comprises at least one of a suspension wrap material, a foam, a plastic, a rubber, or a corrugated material.
 6. The package as defined in claim 1, wherein the inner protective packaging material includes a scratch-resistive protective layer disposed on at least the side adjacent the flat panel product parallel to a major plane of the flat panel product.
 7. The package as defined in claim 1, wherein the outer packaging material comprises at least one of a corrugated paperboard, a corrugated plastic, a laminated fiberboard, a sheet plastic, a shrink wrap material, or a singleface corrugated paper.
 8. The package as defined in claim 1, wherein the size adjustable outer packaging material comprises a first panel and a second panel, the first panel, wherein the first and second panels can be telescoped to resize the package for a selected flat panel product.
 9. The package as defined in claim 1, wherein the flat panel product comprises at least one of a door, a window, a sheet material, and a printed circuit board.
 10. The package as defined in claim 1, wherein the binder comprises a banding material.
 11. The package as defined in claim 1, wherein the outer packaging material comprises one or more pair of slots formed on opposing sides of the outer packaging material to receive the banding material.
 12. The package as defined in claim 1, wherein the inner protective packaging material is sized and dimensioned to circumscribe the edge of the flat panel product.
 13. The package as defined in claim 1, wherein the inner packaging material is sized and dimensioned to provide an air cell around the circumference of the package to protect the edges of the flat panel product.
 14. A package for shipping a flat panel product, the package comprising: an inner protective packaging material sized and dimensioned to be disposed peripherally around the outer edge of the flat panel product; a resizable outer packaging material, provided over the inner protective packaging material and including a plurality of slots; and a binder provided around the outer packaging material in the slots for securing the outer packaging material to the inner protective packaging material to retain the flat panel product within the package and to suspend the inner protective packaging material and the product relative to at least one side wall of the size adjustable outer packaging material, wherein the inner and outer packaging materials form an air cell around the inner flat panel product to protect the product during shipping.
 15. The package for shipping a flat panel product as defined in claim 14, wherein the outer packaging material comprises a plurality of slots sized and dimensioned for receiving the sealing material.
 16. The package for shipping a flat panel product as defined in claim 14, wherein the sealing material comprises a banding material.
 17. The package for shipping a flat panel product as defined in claim 14, wherein the resizable outer package comprises a telescoping package.
 18. A package for shipping a flat panel product, the package comprising: an inner shock-absorbing packaging material disposed around the circumference of the flat panel product; a telescoping outer packaging material. comprising a plurality of slots on at least one pair of opposing edges; and a binding material provided over the outer packaging material, the binding material being received in the slots to bind the outer packaging material over the inner packaging material.
 19. The package for shipping a flat panel product as defined in claim 18, wherein the banding material comprises a plastic banding material.
 20. The package for shipping a flat panel product as defined in claim 18, wherein the outer packaging material comprises a corrugated paperboard.
 21. The package for shipping a flat panel product as defined in claim 18, wherein the inner protective packaging material comprises a resilient material.
 22. The package for shipping a flat panel product as defined in claim 18, wherein the inner protective packaging material further comprises a water resistant inner lining.
 23. A package for shipping a flat panel product, the package comprising: a strip of an inner protective packaging material wrapped peripherally around an outer edge of the flat panel product, said material having side edges laterally spaced from opposing faces of the flat panel product so as to create a protected air space on each side of the flat panel product between the face of the product and a plane defined by the adjacent side edges of the packaging material; an outer packaging material enclosing the inner protective packaging material, said outer packaging material being of a certain lateral size and of an adjustable longitudinal size; a binder wrapped longitudinally around the outer packaging material the outer packaging material having slots in opposed sidewalls at its longitudinal ends to receive said binder said binder supportively engaging said inner protective packaging material in said slots to laterally support said inner protective packaging material and product within said outer protective packaging material.
 24. The package as defined in claim 23, wherein said binder is one or more bands wrapped longitudinally around said outer protective packaging material.
 25. The package as defined in claim 24, wherein said inner protective packaging material is in a position that is laterally spaced from at least one side of a wall of the outer protective packaging material and is supported in said position by the bands. 